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Thread: Jarrad's AE86 resto project

  1. #241
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    Wow! I haven't had an update here for quite a while... So lets go from where I left off.

    I got the headers on, did a bit of other stuff. Had the car wired up by an AE86 mate (not sure if he's on here actually!) and got it started! There was a few weird issues with lights and we couldn't get it started. Turned out the starting issue was having the dizzy in 180deg out... oops! After that it fired first turn!

    After having it started my custom front water outlet had a few pinhole leaks so it had to be drained and re-welded.
    Whilst I'm sure it is fixed, I coated it in JB weld on the outside just to be sure.

    Here's my vac line arrangement - one to each intake/cylinder, then to the booster.

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    This is on the day of start up, before the wiring is tidied up in conduit.
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    First time "Driving" it. With my butt clenched... off to get it's exhaust done. It didn't go very far - too scared as it hasn't been run in and there's so many unknowns with the car still.
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    I didn't really request anything... Ended up a 2.25 inch straight through with two large mufflers. It isn't too loud and I reckon it sounds decent.
    I liked the addition of some ADM spec commodore exhaust tip haha.
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    After the exhaust it was hopefully going straight to be tuned... but alas I could hear the car now... I could here my terribly whining diff.
    Pulled it. 3.7 open diff. May as well change and do all the bearings that as the rest of the car has been anyway!
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    It will be replaced with 4.1 and Cusco 1.5 way LSD.

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    In the meantime while I wait for parts and the diff building, I have changed a few things.
    It's now running a starlet booster for more clearance, as regardless of what filters/intake options I decide on more room is good to have.

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    I also found my gearbox hasn't got the reverse light engagement thing inside the box.. I ain't pulling it, and I ain't pulling it apart.
    So have run a small switch for my reverse lights. They're a must have, and it looks at place in the cockpit when you see it as whole.

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    I was toying with an idea for an airbox as well. But may just run those flat side filters. I don't really want to run no filters, and oiled socks are very restrictive.

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    And here's a pretty-well-complete shot of the engine bay. All wired up.
    A few changes from this image:
    Starlet booster. Likely different air filters at least. Probably a different fuel pressure reg and gauge.

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    So yeah! The car is now on stands with the diff apart.
    Two steps forward and one step back, haha. 3 years on... Ah well, car life.
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    Last edited by Jrad; 12th August 2016 at 10:46 PM.

  2. #242
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    looks good man !!
    what hatch is that ? or did you mould a spoiler onto a hatch ?

  3. #243
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    Here's a bunch of pics! Go nuts, hahaa.
    Not ashamed to say I'm very happy with the end result. There's a lot a work in that. Sikaflex and rivets to hold it down. Then mostly fibreglassed and a bit of filler to get it perfect. It came out very well and looks like a one piece moulded part.

    Click image for larger version. 

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  4. #244
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    well done man ! came out heaps good !!

    whole car looks great.

  5. #245
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    Thanks dude! Getting pretty keen now

  6. #246
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    Man I love this thing! Great work dude...

  7. #247
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    hey man whats your final thoughts on the knox carpet, im thinking of getting some.

    did you get the loop pile ?.


    cheers.

  8. #248
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    Hey, yeah. Pretty happy with it. Make sure you get some underfelt though. I had to double that up in the footwells. I got the loop pile. It's closer to OEM.

    I've also fitted plush pile into a Pontiac and it's harder to work with and thicker.

  9. #249
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    Wow, bit slack on updates. I dropped my diff off with a replacement 4.1 ratio that turned out to be not good. It wouldn't pattern up in any way, shape or form. Ended up sourcing another so there was a bit of a delay there. But now the diff is in and sounds much better.

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    In the meantime, I wanted to make an airbox for my carb set up. But I'm not sure that I will end up using it due to clearance and fitment issues. I may have another go at making it.

    Anyway, for the sake of others and the exercise. I made a guide skeleton from cardboard and MDF, and foamed a urethane based expanding foam into it. Then cut it back to the desired shape. Trust me to believe the cans instructions, it really does expand a lot.


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    After cutting it down and test fitting it.

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    I think wrapped it in glad wrap so the fibreglass wouldn't stick, and moulded over the top. fitment is generally okay.
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    This is a laser-cut base plate I got for mounting/testing purposes and may end up going with something based off this instead.
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    Anyway, this is now what's keeping it from running... I wanted to install a speco water temp gauge, as well as keep the dash gauge. The bloody adapter sheared off in the housing! such a pain... So I think I'll just tap it out and put a sensor in without an adapter.

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  10. #250
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    OK! It's damn near time to close this chapter! May as well finish the book haha.

    I got the diff in, all the water system sorted and sent it to be finished off/tuned at Allcraft Automotive in Moorabbin - as reccommended to me from a few people due to the Mikunis on the car.

    They were fantastic in wanting to get the car RIGHT. Turn key and go!
    He reworked a few things, like the throttle linkages and pedals. My brakes were seized from being rebuild almost 5 years ago. Fuel system was simplified. I had a weird wiring issue with my headlights too.
    Carbs were cleaned, valves were shimmed, cams timed, speedo cable replaced and a few other small things.

    Anyway! Winners are grinners. I had my first real drive of the car. It was such an awesome feeling - so many unknown noises and stuff, but it already feels heaps of fun to drive.
    I am suspicious that the gearbox has straight cut 1st, 2nd and 3rd gears in it. I did buy it from a guy that raced AE86s and it was meant to be rebuilt.. so who knows. It sounds pretty wicked haha.

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    I ended up not stuffing around with the airbox and made these air cleaners fit.
    The dyno showed they were a bit restrictive, sapping around 5kw at 7500rpm. I will try shorter velocity stacks inside them.

    The good news is... I made 102rwkw tuned on BP Ultimate 98.

    Here's a short clip taking off/engine noise up hill.



    It's now just finally awaiting RWC/rego when I have the time to organise that.

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